Monitoring tool usage

ABSTRACT

Methods and systems for monitoring tool device usage and, in particular, methods and systems including at least one sensor mechanism configured to detect at least one operational parameter of the tool device. Information regarding usage of the tool device may be communicated to a processing unit and further communicated to a network-connected storage and/or to a display device.

CROSS REFERENCE TO RELATED APPLICATIONS

The present application claims the benefit of co-pending U.S.provisional application No. 62/149,496, filed on Apr. 17, 2015, theentire disclosure of which is incorporated by reference as if set forthin its entirety herein.

FIELD

This disclosure relates to methods and systems for monitoring usage of atool device and, in particular, methods and systems including at leastone sensor mechanism operably connected to a tool device to detect atleast one operational parameter of the tool device.

BACKGROUND

Modern factories and other types of manufacturing facilities areincreasingly connected with automated technologies. Although certainsteps of manufacturing processes are automated, human operators arenonetheless still involved. For example, it is often impractical forrobotic systems or machines to perform every step of a manufacturingprocess, and it may be more effective for a human operator to perform acertain step. These human operators may rely on various tool devices toperform the step(s).

It may therefore be desirable to monitor tool device usage. Informationregarding tool device usage may be helpful to, for example, ensure thatusers are being productive and/or consistently following a standard setof work instructions, ensure that users are using the tool device in asafe manner, ensure that the tool devices are functioning properly, torecognize when a tool device needs replacement (e.g., due to amalfunction or a low power level), and to provide other forms ofpreventive maintenance.

However, current precision tools with feedback loops are expensive andcomplicated to use. These existing tools may require training to use andmay rely on complex processing steps that are difficult to implement.

Simpler sensing mechanisms that are decoupled from tool device exist,but do not provide much information regarding tool device usage. Forexample, simple torque meters are available, but they only providesingle, non-continuous readings. In other words, they do not provide afeedback loop and only provide information regarding torque at a singlepoint in time. These existing sensor mechanisms are not modular and aretypically not able to be used across multiple types of tool devices.

A need exists, therefore, for methods and systems for monitoring tooldevice usage that overcome these disadvantages.

SUMMARY

This summary is provided to introduce a selection of concepts in asimplified form that are further described below in the DetailedDescription section. This summary is not intended to identify or excludekey features or essential features of the claimed subject matter, nor isit intended to be used as an aid in determining the scope of the claimedsubject matter.

In one aspect, embodiments of the present invention relate to a systemfor monitoring tool usage, the system including at least one sensormechanism operably and externally connected to a tool device such thatthe at least one sensor mechanism is able to detect at least oneoperational parameter of the tool device in substantially real time; anetwork-connected storage for storing information regarding theoperational parameter of the tool device detected by the at least onesensor mechanism; and a communication mechanism configured tocommunicate information regarding the operational parameter of the tooldevice detected by the at least one sensor mechanism to thenetwork-connected storage.

In one embodiment, the at least one operational parameter includesmovement of the tool device, and the at least one sensor mechanism isselected from the group consisting of an accelerometer, magnetometer,photodetector and a gyroscope to measure the movement of the tooldevice.

In one embodiment, the at least one operational parameter includes powerconsumption of the tool device and the at least one sensor mechanism isa power meter mechanism.

In one embodiment, the at least one operational parameter includeselectrical signals communicated from the tool device.

In one embodiment, the system further comprises a processing unitconfigured to determine a state of the tool device based on theinformation regarding the at least one operational parameter of the tooldevice. In one embodiment, the state of the tool device is a function ofat least one of orientation of the tool device, location of the tooldevice, temperature of the tool device, power level of the tool device,and operation of the tool device. In one embodiment, the system furthercomprises a control unit configured to prevent use of the tool deviceupon the processing unit determining the tool device is in a certainstate.

In one embodiment, the at least one sensor mechanism is configured as adeformable and extendable substrate to be removably connected todifferent types of tool devices.

In one embodiment, the tool device is selected from the group consistingof a machine, an actuator, a hand tool, and a power tool.

In another aspect, embodiments of the invention relate to a method formonitoring tool usage. The method includes operably connecting at leastone sensor mechanism to a tool device; detecting, via the at least onesensor mechanism and in substantially real time, at least oneoperational parameter of the tool device; and communicating, via acommunication mechanism, information regarding the at least oneoperational parameter of the tool device to a network-connected storage.

In one embodiment, the at least one operational parameter includesmovement of the tool device, and the at least one sensor mechanism isselected from the group consisting of an accelerometer, magnetometer,photodetector and a gyroscope to measure the movement of the tooldevice.

In one embodiment, the at least one operational parameter includes powerconsumption of the tool device and the at least one sensor mechanism isa power meter mechanism.

In one embodiment, the at least one operational parameter includeselectrical signals communicated from the tool device.

In one embodiment, the method further comprises the step of determining,via a processing unit, a state of the tool device based on theinformation regarding the at least one operational parameter of the tooldevice. In one embodiment, the state of the tool device is a function ofat least one of orientation of the tool device, location of the tooldevice, temperature of the tool device, power level of the tool device,and operation of the tool device. In one embodiment, the method furthercomprises the step of changing a parameter of the tool device upon theprocessing unit determining the tool device is in a certain state. Thismay involve, e.g., preventing, via a control unit, use of the tooldevice.

In one embodiment, the at least one sensor mechanism is configured as adeformable and extendable substrate to be removably connected todifferent types of tool devices.

In one embodiment, the tool device is selected from the group consistingof a machine, an actuator, a hand tool, and a power tool.

In yet another aspect, embodiments of the present invention relate to asensor mechanism for monitoring usage of a tool device. The sensormechanism is configured as a deformable and extendable substrate to beremovably connected to different types of tool devices, the sensormechanism further configured to detect at least one operationalparameter of a tool device and to communicate information regarding theat least one operational parameter of the tool device to anetwork-connected storage.

These and other features and advantages, which characterize the presentnon-limiting embodiments, will be apparent from a reading of thefollowing detailed description and a review of the associated drawings.It is to be understood that both the foregoing general description andthe following detailed description are explanatory only and are notrestrictive of the non-limiting embodiments as claimed.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings are not intended to be drawn to scale. In thedrawings, each identical or nearly identical component that isillustrated in various figures may be represented by a like numeral. Forpurposes of clarity, not every component may be labeled in everydrawing. Various embodiments will now be described, by way of example,with reference to the accompanying drawings, in which:

FIG. 1 illustrates a system for monitoring tool device usage inaccordance with one embodiment;

FIG. 2 illustrates a system for monitoring tool device usage inaccordance with another embodiment;

FIG. 3 illustrates a system for monitoring tool device usage inaccordance with yet another embodiment;

FIG. 4 illustrates multiple views of a sensor mechanism in accordancewith one embodiment;

FIG. 5 illustrates a sensor mechanism in accordance with anotherembodiment;

FIG. 6 illustrates a sensor mechanism operably connected to a drillpress in accordance with one embodiment;

FIG. 7 depicts a flowchart of a method of monitoring tool device usagein accordance with one embodiment;

FIG. 8 depicts a flowchart of a method of monitoring tool device usagein accordance with another embodiment; and

FIG. 9 depicts a flowchart of a method of monitoring tool device usagein accordance with yet another embodiment.

In the drawings, like reference characters generally refer tocorresponding parts throughout the different views. The drawings are notnecessarily to scale, emphasis instead being placed on the principlesand concepts of operation.

DETAILED DESCRIPTION

Various embodiments are described more fully below with reference to theaccompanying drawings, which form a part hereof, and which show specificexemplary embodiments. However, the concepts of the present disclosuremay be implemented in many different forms and should not be construedas limited to the embodiments set forth herein; rather, theseembodiments are provided as part of a thorough and complete disclosure,to fully convey the scope of the concepts, techniques andimplementations of the present disclosure to those skilled in the art.Embodiments may be practiced as methods, systems or devices.Accordingly, embodiments may take the form of a hardware implementation,an entirely software implementation or an implementation combiningsoftware and hardware aspects. The following detailed description is,therefore, not to be taken in a limiting sense.

Reference in the specification to “one embodiment” or to “an embodiment”means that a particular feature, structure, or characteristic describedin connection with the embodiments is included in at least one exampleimplementation or technique in accordance with the present disclosure.The appearances of the phrase “in one embodiment” in various places inthe specification are not necessarily all referring to the sameembodiment.

Some portions of the description that follow are presented in terms ofsymbolic representations of operations on non-transient signals storedwithin a computer memory. These descriptions and representations areused by those skilled in the data processing arts to most effectivelyconvey the substance of their work to others skilled in the art. Suchoperations typically require physical manipulations of physicalquantities. Usually, though not necessarily, these quantities take theform of electrical, magnetic or optical signals capable of being stored,transferred, combined, compared and otherwise manipulated. It isconvenient at times, principally for reasons of common usage, to referto these signals as bits, values, elements, symbols, characters, terms,numbers, or the like. Furthermore, it is also convenient at times, torefer to certain arrangements of steps requiring physical manipulationsof physical quantities as modules or code devices, without loss ofgenerality.

However, all of these and similar terms are to be associated with theappropriate physical quantities and are merely convenient labels appliedto these quantities. Unless specifically stated otherwise as apparentfrom the following discussion, it is appreciated that throughout thedescription, discussions utilizing terms such as “processing” or“computing” or “calculating” or “determining” or “displaying” or thelike, refer to the action and processes of a computer system, or similarelectronic computing device, that manipulates and transforms datarepresented as physical (electronic) quantities within the computersystem memories or registers or other such information storage,transmission or display devices. Portions of the present disclosureinclude processes and instructions that may be embodied in software,firmware or hardware, and when embodied in software, may be downloadedto reside on and be operated from different platforms used by a varietyof operating systems.

The present disclosure also relates to an apparatus for performing theoperations herein. This apparatus may be specially constructed for therequired purposes, or it may comprise a general-purpose computerselectively activated or reconfigured by a computer program stored inthe computer. Such a computer program may be stored in a computerreadable storage medium, such as, but is not limited to, any type ofdisk including floppy disks, optical disks, CD-ROMs, magnetic-opticaldisks, read-only memories (ROMs), random access memories (RAMs), EPROMs,EEPROMs, magnetic or optical cards, application specific integratedcircuits (ASICs), or any type of media suitable for storing electronicinstructions, and each may be coupled to a computer system bus.Furthermore, the computers referred to in the specification may includea single processor or may be architectures employing multiple processordesigns for increased computing capability.

The processes and displays presented herein are not inherently relatedto any particular computer or other apparatus. Various general-purposesystems may also be used with programs in accordance with the teachingsherein, or it may prove convenient to construct more specializedapparatus to perform one or more method steps. The structure for avariety of these systems is discussed in the description below. Inaddition, any particular programming language that is sufficient forachieving the techniques and implementations of the present disclosuremay be used. A variety of programming languages may be used to implementthe present disclosure as discussed herein.

In addition, the language used in the specification has been principallyselected for readability and instructional purposes and may not havebeen selected to delineate or circumscribe the disclosed subject matter.Accordingly, the present disclosure is intended to be illustrative, andnot limiting, of the scope of the concepts discussed herein.

Features of the present invention relate generally to a sensor mechanismconfigured to operably connect with a plurality tool devices to gatherinformation regarding at least one operational parameter of the tooldevice. Features of the present invention also relate to methods andsystems for monitoring usage of the tool device.

In various embodiments, the sensor mechanism may be elastic andextendable to change shape and size to connect to a variety of differenttypes of tool devices and to different portions of said tool devices. Inthese embodiments, the sensor mechanism may act as a “wearable” sensordevice for a particular tool device and may gather information regardingthe tool device's usage in real time.

In the context of the present application, the term “tool device” mayrefer to any type of machine (e.g., used in manufacturing processes),power tool, hand tool, tool actuator, or the like.

In the context of the present application, the term “tool topology” mayrefer to characteristics of a tool device such as how it is grasped byusers, how it is used, how it is actuated, how it is powered, how safetyis provided, how the tool device interacts with a workpiece, etc. Thisdiscussion is not limited to a single type of tool. Topology may berelevant for single-hand tools, two-hand tools, spindles (rotary tools),triggered devices, or the like.

In the context of the present application, the term “operationalparameter” may refer to how the tool device is operated. Operationalparameters may refer to whether the tool device is on/off, whether thetool device is active, how long the tool device has been used, theorientation of the tool device, how the tool device is held by a user,the location of the tool device, the power level of the tool device, thepower consumption of the tool device, the movement of the tool device,or physics of the tool device (e.g., displacement, velocity,acceleration, illuminance or irradiance (or other information regardingincident light on a surface), etc.). This list is non-exhaustive and itis contemplated that other types of operational parameters may bedetected without departing from the scope of the invention.

In the context of the present application, the term “state” of the tooldevice may refer to a characteristic or mode of the tool device that isdependent on at least one operational parameter of the tool device. Forexample, if an operational parameter of a tool device is rotations perminute (RPM), and the RPM is above a certain level, the state of thetool device may be “active” or “in use.” As another example, if thedetected operational parameter indicates that the tool device is upsidedown or otherwise oriented in an unsafe orientation, the state may be“unsafe for use.” As yet another example, if the detected operationalparameter indicates a power level that is below a certain level, thestate may be “in need of charging or battery replacement.” The tooldevice state may also provide manufacturing process context whencombined with work instructions. For example, a state could reportevents such as “tool picked up by operator at a certain work step.”

Features of the present invention therefore enable feedback regardingtool device usage, along with user action, in real time and in anon-invasive manner. It may be desirable to have this type ofinformation to, for example, ensure users are being productive, ensureusers are following a standard set of work instructions, ensure usersare using the tool device in a safe manner, ensure the tool devices arefunctioning properly, and to recognize when a tool device may needreplacement (e.g., due to low power level). This type of feedback may bemade available to Manufacturing Execution Systems (MESs), human-machineinterfaces (HMIs), and/or other interfaces used to in turn guide anoperator to perform a certain step in the manufacturing process.

Although the features of the invention are described as beingimplemented in manufacturing facilities such as factories, it iscontemplated that the features of the invention may be used in otherapplications. Applications such as those in farming, medicine, andconstruction, for example, may benefit from the features of theinvention.

FIG. 1 illustrates components of a system 100 for non-invasivelymonitoring tool device usage in accordance with one embodiment. In thisparticular embodiment, an operator (user) 102 may operate an actuator104 to actuate a tool device (e.g., a machine) 106. When the tool device106 is actuated, power is drawn and measured by the power meter 108.Specifically, when the tool device 106 is actuated, current flows in aloop from the power source and returned during operation of the tooldevice 106. This current draw can fluctuate depending on the operationof the tool device 106. Additionally, voltage (in conjunction with theDC and AC components can be used to calculate power (W) and othersimilar calculations such as, but limited to, RMS power, peak power, orthe like. Further, by measuring the AC and digitizing this signal via ananalog-to-digital converter, digital techniques, such as moving from thetime-domain to frequency domain, are possible. The power meter 108 mayreport the power draw to the cell 110. The cell 110 serves as a gatewaydevice that connects existing and new hardware (i.e., tool devices 106)to the network-connected storage 114. The cell 110 collects informationfrom the factory floor (such as power drawn by the tool device) andcommunicates that information to the network-connected (e.g.,cloud-based) storage 114. The cell 110 may also include processingcomponents to determine the state of the tool device 106 based on themeasured operational parameters.

This information is further communicated, via an i/net connection 112(i.e., a local area network connection, wireless connection, internetconnection, etc.) to a network-connected storage 114 and/or may bepresented on display device 116.

In this embodiment, the operator (user) 102 may be located amanufacturing facility such as a factory or the like. The actuator 104may be any type of device operably connected to any type of tool device106 to control operation of the tool device 106.

In this embodiment, tool device 106 usage is monitored based on themeasurement of the power drawn by the tool device 106. Informationregarding the power drawn may be communicated to the cell 110.

The cell 110 can connect to existing factory-floor equipment in avariety of ways. For example, the cell 110 can connect using an existingindustrial network protocol such as MTConnect, OPC-UA, Modbus, CAN bus,and others. The cell 110 can also connect to standard peripheral devicessuch as RFID readers and/or barcode scanners that have standardoperating-systems such as HID implemented thereon. In addition to thesemethods, the cell 110 can also be implemented as a simpler interface by,for example, detecting the voltage level or switching to a binaryoutput. This is an example of a parallel input via field-conditionedinputs and outputs (and a non-serialized data input or output stream).

The cell 110 may communicate information regarding the tool deviceusage, via an i/net connection 112 to the network-connected storage 114.Information regarding usage of the tool device 106 may also becommunicated to and presented on a display device 116. The displaydevice 116 may be configured as a PC, laptop, tablet, smartphone,smartwatch, or the like, and may allow a viewer to view informationregarding tool device 106 in substantially real time. Information may becommunicated to (and from) the display device 116 via any type ofhardwired or wireless connection, e.g., Ethernet, 802.11x, Bluetooth,etc.

FIG. 2 presents another embodiment of a system 200 for monitoring tooldevice usage. Similar to the system 100 of FIG. 1, an operator 202 mayoperate an actuator 204 to control a tool device 206. In thisembodiment, however, a cell 208 provides a bypass 214 to the actuator204 by virtue of the actuator's connection to a tool device controller210. The cell 208 may read the actuator's communications with the tooldevice controller 210 to obtain information regarding usage of the tooldevice 206.

Communication link 212 represents an original communication path betweenthe actuator 204 and the tool device controller 210. The system 200,however, replaces this path with a bypass 214 that allows the system 200to intercept information transmitted between the actuator 204 and thetool device controller 210 using the cell 208. Thus, data concerning theusage of the tool device 206 becomes available to the cell 208 in thecontext of a specific step in a particular manufacturing process.

In this embodiment, the cell monitors an existing tool device byconnecting to the tool device's 206 output lines (e.g., those used toactuate relays, valves, etc.), communication lines (such as, e.g.,RS-232 serial communication lines), or by monitoring power consumptionby the tool device 206 and/or its components.

As in the system 100 of FIG. 1, information regarding usage of the tooldevice 206 may be communicated via an i/net connection 216 to anetwork-connected storage 218 and also communicated to and presented ona display device 220. The display device 220 may be configured as a PC,laptop, tablet, smartphone, smartwatch, or the like, and may allow aviewer to view information regarding tool device 206 in substantiallyreal time.

FIG. 3 presents a system 300 for monitoring tool device usage inaccordance with another embodiment. Similar to FIGS. 1 and 2, anoperator 302 may actuate an actuator 304 to operate a tool device 306(illustrated as a power drill). In this embodiment, the tool device 306may include a tool latching mechanism 308 to attach at least one sensor310 (discussed below) to the tool device 306. The at least one sensor310 may non-invasively monitor the movement(s) and operation of the tooldevice 306 so that the state of the tool device 306 may be determined.

The tool device 306 may include or otherwise be in communication with atool sensor controller 312, which in turn may be in communication with abattery 314 to monitor power levels of the tool device 306, a wirelessradio interface 316 to wirelessly communicate information regarding thetool device 306, and at least one sensor device 310. The at least onesensor device 310 may be, for example, an accelerometer 320, a gyroscope322, a magnetometer 324, and/or a photodetector 326. The type of sensordevice(s) used may vary and may depend on the type of tool device alongwith the operational parameter(s) to be measured.

The components of the system 300 may be in communication with the cell328 via any hardwired or wireless connection. Communications regardingtool device 306 usage and other information may be communicated from thewireless radio interface 316 to the cell 328, for example. As in theembodiments of FIGS. 1 and 2, the cell 328 may process the obtainedinformation to determine the state of the tool device. This informationmay be further communicated via an i/net communication 330 to anetwork-connected storage 332. This information may also be communicatedto and presented on a display device 334.

FIGS. 4A-C illustrate multiple views of an attachable sensor mechanism400 in accordance with one embodiment. The term “attachable” simplyrefers to the sensor mechanism's ability to directly connect to orotherwise interface with a tool device, such as in the embodimentillustrated in FIG. 3, and without adversely affecting the tool device'sability to function.

The sensor mechanism 400 may include an elastic portion 402 with allnecessary electronics and circuitry printed or otherwise includedthereon. The elastic portion 402 may further include a connectionmechanism like buckles 404 a and 404 b with pins 406, or be attached toa tool device via an adhesive.

The sensor mechanism 400 may include a housing portion 408 that includescomponents such as a battery 410, transceiver 412, vibration sensor 414,gyroscope 416, acceleration sensor 418, and GPS sensor 420. These typesof components are merely exemplary and it is contemplated that othertypes of components may be configured as part of the sensor mechanism400 depending on the application (e.g., depending on the type of tooldevice, the operational parameter being measured, etc.).

Regardless of the exact configuration of the sensor mechanism 400, it iscontemplated that the sensor mechanism 400 is length-adjustable andconfigurable so it can connect to different types of tool devices and atdifferent locations on said tool devices, depending on the topology ofthe tool device. FIG. 4B shows the sensor mechanism 400 extending inlength (indicated by arrows) by virtue of the elastic portion 402. Theelastic portion 402 may extend under tensile stress (e.g., as a userpulls on the ends of the sensor mechanism 400), and then return to itsoriginal shape and size when the stress is removed.

FIG. 4C illustrates the sensor mechanism 400 in a closed position. Thebuckles 404 a and 404 b may connect with each other via pins 406 oranother connection mechanism so that the sensor mechanism 400 cansecurely attach to or otherwise connect with a tool device (not shown inFIG. 4C).

Additionally or alternatively, the length of the sensor mechanism may beadjusted via a spool and spring configuration; or a configuration ofstraps and ratchets that enable the strap to be pulled to a certainlength and then locked at a certain length, or any of a variety ofmechanism for adjusting length known to one of ordinary skill.

FIG. 5, for example, illustrates a sensor mechanism 500 in accordancewith another embodiment of the invention. The sensor mechanism 500 maybe similar to the sensor mechanism 400 of FIG. 4 in that it may includea housing 502 with various sensor devices. However, in this embodiment,the sensor mechanism 500 may include straps 504 (e.g., made of leatheror neoprene foam) extendable by a buckle 506. Also in this embodiment,the sensor mechanism 500 may be secured around a tool device viaconnection mechanisms 508 a and 508 b.

FIG. 6 illustrates a sensor mechanism attached to a tool device inaccordance with one embodiment of the invention. FIG. 6 illustrates adrill press machine 600 with a sensor mechanism 602 such as the oneillustrated in FIG. 4 or 5 attached. In this particular embodiment, thesensor mechanism 602 is secured to a spindle portion 604 of the drillpress 600. The sensor mechanism 602 may therefore be configured todetect the RPM of the spindle 604 during operation of the drill press600 and/or detect when the spindle portion 604 is lowered/raised duringoperation of the drill press 600.

FIG. 7 depicts a flowchart of a method 700 of monitoring tool deviceusage in accordance with one embodiment. Step 702 involves operablyconnecting at least one sensor mechanism to a tool device. The sensormechanism may be operably connected to a tool device by any of thetechniques previously described or other analogous techniques apparentto one of ordinary skill.

If the sensor mechanism is going to be attached to the tool device (asin FIG. 6), the sensor mechanism may be operably connected to the tooldevice in a variety of ways based on the topology of the tool device.For example, the sensor mechanism may be connected to a spindle of thetool device (as in FIG. 6) or a trigger of the tool device. The sensormechanism may also be connected to a handle of the tool device to, forexample, ensure the operator is using the tool device with two hands. Inthese embodiments, the sensor mechanism may be configured as an elasticand adjustable article to change shape and size to be able to connect toa variety of tool devices.

Step 704 involves detecting, via the at least one sensor mechanism andin substantially real time, at least one operational parameter of thetool device. The terms “in substantially real time” may mean in realtime or with some minimal delay that does not significantly diminish thevalue of the obtained information regarding the operational parameter ofthe tool device.

The operational parameter detected may depend on the type of tooldevice, the type of sensor mechanism, and the location of the sensormechanism on the tool device. For example, if the tool device is a powerdrill such as the one of FIG. 3, there may be at least one piezoelectricelement located at various positions on the power drill. Thesepiezoelectric elements may detect, for example, pressure applied by theoperator's hands when holding and operating the tool device. Thisinformation may be used to determine whether the operator is holding thetool device in the correct location(s) and/or holding the tool devicewith two hands.

Similarly, a tool device such as a power drill may be equipped withgyroscope devices. These gyroscopes may detect whether an operator isusing the tool device in the correct orientation (i.e., holding itcorrectly), for example. Or, these gyroscope devices may simply detectwhether the tool device is being used and/or how long it has been used.

As another example, the sensor mechanism may be operably connected to,for example, the trigger, spindle, and/or a bit device to detect, e.g.,the RPM of a moving part. If the sensor mechanism is attached to aspindle, it may include a gyroscope and/or an accelerometer. Thisinformation may be used to determine whether the operator is actuallyusing the power drill, for example.

Step 706 involves communicating, via a communication mechanism,information regarding the at least one operational parameter of the tooldevice to a network-connected storage. This information may becommunicated wirelessly, for example. Information regarding the tooldevice usage may be stored for later analysis, and/or may be displayedon a display device. Therefore, an operator or other interested party(such as an operator's supervisor) may monitor usage of the tool devicein substantially real time.

FIG. 8 depicts a flowchart of a method 800 of monitoring tool deviceusage in accordance with another embodiment. Steps 802, 804, and 806 aresimilar to steps 702, 704, and 706, respectively, of FIG. 7 and are notrepeated here.

Step 808 involves, determining, via a processing unit, a state of thetool device based on the information regarding the at least oneoperational parameter of the tool device. The state of the tool devicemay depend on the type of tool device, the type of sensor mechanism, andthe location of the sensor mechanism on the tool device.

As mentioned previously, the “state” as it relates to a tool device, mayrefer to whether the tool device is: on or off; operating above orwithin safe speed range; short circuiting; operating at or above a safepower level; being held correctly, etc. The tool device state may bedetermined by a processing unit and is based on the at least oneoperational parameter of the tool device.

The processing unit (e.g., the cells 110, 208, and 328 of FIGS. 1, 2,and 3, respectively) may be any specifically configured processor orhardware device capable of analyzing the operational parameter(s) todetermine the state of the tool device. The processing unit may includea microprocessor, a field programmable gate array (FPGA),application-specific integrated circuit (ASIC), or other similar device.In some embodiments, such as those relying on one or more ASICs, thefunctionality described as being provided in part via software mayinstead be configured into the design of the ASICs, and as such, anyassociated software may be reduced or omitted.

The processing unit may, for example, analyze information obtained bypiezoelectric elements positioned on a power drill (if applicable). Inthis embodiment, the “state” of the tool device may be whether the tooldevice is being held by the user correctly or incorrectly. Any class oftransducers that convert mechanical signals into electrical signals maybe used as they are computationally simple and power-efficient. Forexample, these types of transducers can be used to “wake” any applicableprocessing devices and/or connect any applicable sensor devices, therebylengthening battery life, among other features.

Information regarding the state of the tool device may be communicatedto storage and/or communicated to a display device. Informationregarding the state of the tool device may be presented on the displaydevice in variety of ways. For example, if the tool device is in apotentially dangerous state (e.g., overheating, being held incorrectly),the display device may communicate a message to that effect in a varietyof ways. The display device may issue an audio alert, a visual alert(e.g., in the form of color patterns), and/or a haptic-based alert,along with recommendations of how to make the tool device return to asafe state.

FIG. 9 depicts a flowchart of a method 900 of monitoring tool deviceusage in accordance with one embodiment. Steps 902, 904, 906, and 908are similar to steps 802, 804, 806, and 808, respectively, of FIG. 8 andare not repeated here.

Step 910 is optional and involves preventing, via a control unit, use ofthe tool device upon the processing unit determining the tool device isin a certain state. For example, if the state of the tool device is“held incorrectly,” the control unit may prevent power from beingsupplied to the tool device until the tool device is held correctly. Asanother example, if the state of the tool device is “overheated,” thecontrol unit may prevent operation of the tool device until the state ofthe tool device is no longer “overheated.” This control unit may beconfigured as part of the cell, or as a separate device in communicationwith the cell and in connection with the tool device.

In other embodiments, other parameters of the tool may be varied if theprocessing unit determines the tool device is in a certain state. Forexample, an orientation behavior could change a speed setting of adrill.

The methods, systems, and devices discussed above are examples. Variousconfigurations may omit, substitute, or add various procedures orcomponents as appropriate. For instance, in alternative configurations,the methods may be performed in an order different from that described,and that various steps may be added, omitted, or combined. Also,features described with respect to certain configurations may becombined in various other configurations. Different aspects and elementsof the configurations may be combined in a similar manner. Also,technology evolves and, thus, many of the elements are examples and donot limit the scope of the disclosure or claims.

Embodiments of the present disclosure, for example, are described abovewith reference to block diagrams and/or operational illustrations ofmethods, systems, and computer program products according to embodimentsof the present disclosure. The functions/acts noted in the blocks mayoccur out of the order as shown in any flowchart. For example, twoblocks shown in succession may in fact be executed substantiallyconcurrent or the blocks may sometimes be executed in the reverse order,depending upon the functionality/acts involved. Additionally, oralternatively, not all of the blocks shown in any flowchart need to beperformed and/or executed. For example, if a given flowchart has fiveblocks containing functions/acts, it may be the case that only three ofthe five blocks are performed and/or executed. In this example, any ofthe three of the five blocks may be performed and/or executed.

A statement that a value exceeds (or is more than) a first thresholdvalue is equivalent to a statement that the value meets or exceeds asecond threshold value that is slightly greater than the first thresholdvalue, e.g., the second threshold value being one value higher than thefirst threshold value in the resolution of a relevant system. Astatement that a value is less than (or is within) a first thresholdvalue is equivalent to a statement that the value is less than or equalto a second threshold value that is slightly lower than the firstthreshold value, e.g., the second threshold value being one value lowerthan the first threshold value in the resolution of the relevant system.

Specific details are given in the description to provide a thoroughunderstanding of example configurations (including implementations).However, configurations may be practiced without these specific details.For example, well-known circuits, processes, algorithms, structures, andtechniques have been shown without unnecessary detail in order to avoidobscuring the configurations. This description provides exampleconfigurations only, and does not limit the scope, applicability, orconfigurations of the claims. Rather, the preceding description of theconfigurations will provide those skilled in the art with an enablingdescription for implementing described techniques. Various changes maybe made in the function and arrangement of elements without departingfrom the spirit or scope of the disclosure.

Having described several example configurations, various modifications,alternative constructions, and equivalents may be used without departingfrom the spirit of the disclosure. For example, the above elements maybe components of a larger system, wherein other rules may takeprecedence over or otherwise modify the application of variousimplementations or techniques of the present disclosure. Also, a numberof steps may be undertaken before, during, or after the above elementsare considered.

For example, the following exemplary user scenarios may be realized byincorporating the above-discussed features. As mentioned previously, thefeatures of the invention may be used to determine whether the correcttool was picked up, and may be measured in a variety of ways. Forexample, there may be a sensor package on a hand-held tool such as thedrill of FIG. 3C that contains an accelerometer and a gyroscope. Anon-board processing device may watch for changes in the sensor valuesand transmit an event indicating that the tool was picked up.

Or, each tool device may include, on the handle, a pressure sensor thatis connected to a circuit that transmits a unique ID when a hand pressesor otherwise engages it, and a remote (or local) hub may receive thatinformation and pass it along with a timestamp to the internet. Inanother embodiment, a user wear may a band on their wrist thatcontinuously measures local electromagnetic noise. When the user picksup a device, the band may measure a change in the noise spectrum, andthen transmit the event to a base station elsewhere to be forwarded tothe internet.

In yet another embodiment, a device embedded in the wiring of a tooldevice may monitor the operation of the tool device and communicate theactivity along with IDs to an internet-connected base station. Or, eachtool device may be outfitted with an RFID tag and the operator may wearan RFID reader. When the tool device is picked up, the RFID reader mayread the tag and communicate the event over the internet.

Features of the present invention may also be used to gather informationregarding anomalous events. For example, a sensor for augmenting a toolmay include or otherwise be configured with a small camera that isinstructed to take/record imagery of the workpiece upon the occurrenceof an unexpected event for later debugging. This imagery may betransmitted over the internet in at least substantially real time foranalysis.

Features of the present invention may also be used to determinevariation in an operator's operation of a tool device (e.g., for qualitycontrol purposes). Specifically, features of the invention may be usedto detect (and quantify) variations in tasks such as cutting, rolling,pressing, etc. A strain-gauge or a flexible combination of strain gaugesmay measure, via a trivial amount of support/conditioning circuitry, thevariation in torque during operation of a tool device. The velocity ofcertain tool devices may also be monitored. For example, velocity of adrill press may be monitored to ensure it is applied at a constant speedto minimize risk of potential component failure. This may beaccomplished by an optical encoder and/or a gyroscope that measures thevelocity or angular momentum of the moving part. In other embodiments,voltage due to movement of a tool device may be detected. It iscontemplated that thresholds may be applied along with feedback/controlmechanisms to halt operation of the tool device upon certain parametersbeing exceeded.

Features of the present invention may also be used to determine how longtool devices are idle between processes (i.e., how much they're beingused). As mentioned previously, this may be done by the amount of powerdrawn or measured passively via a transducer that converts mechanicalenergy (vibrations) into an electrical signal to be measured.

The features of the present invention may also include log-in systems tomonitor which operator(s) are using the tool devices.

Having been provided with the description and illustration of thepresent application, one skilled in the art may envision variations,modifications, and alternate embodiments falling within the generalinventive concept discussed in this application that do not depart fromthe scope of the following claims.

1. A system for monitoring tool usage, the system comprising: at leastone sensor mechanism operably and externally connected to a tool devicesuch that the at least one sensor mechanism is able to detect at leastone operational parameter of the tool device in substantially real time;a network-connected storage for storing information regarding theoperational parameter of the tool device detected by the at least onesensor mechanism; and a communication mechanism configured tocommunicate information regarding the operational parameter of the tooldevice detected by the at least one sensor mechanism to thenetwork-connected storage.
 2. The system of claim 1, wherein the atleast one detected operational parameter is movement of the tool device.3. The system of claim 2, wherein the at least one sensor mechanism isselected from the group consisting of an accelerometer, magnetometer,photodetector, transducer, and a gyroscope to measure the movement ofthe tool device.
 4. The system of claim 1, wherein the at least oneoperational parameter includes power consumption of the tool device andthe at least one sensor mechanism is a power meter mechanism.
 5. Thesystem of claim 1, wherein the at least one operational parameterincludes electrical signals communicated from the tool device.
 6. Thesystem of claim 1, further comprising a processing unit configured todetermine a state of the tool device based on the information regardingthe at least one operational parameter of the tool device.
 7. The systemof claim 5, wherein the state of the tool device is a function of atleast one of orientation of the tool device, location of the tooldevice, temperature of the tool device, power level of the tool device,and operation of the tool device.
 8. The system of claim 6, furthercomprising a control unit configured to change a parameter of the tooldevice upon the processing unit determining the tool device is in acertain state.
 9. The system of claim 1, wherein the at least one sensormechanism is configured as a deformable and extendable substrate to beremovably connected to different types of tool devices.
 10. The systemof claim 1, wherein the tool device is selected from the groupconsisting of a machine, an actuator, a hand tool, and a power tool. 11.A method for monitoring tool usage, the method comprising: operablyconnecting at least one sensor mechanism to a tool device; detecting,via the at least one sensor mechanism and in substantially real time, atleast one operational parameter of the tool device; and communicating,via a communication mechanism, information regarding the at least oneoperational parameter of the tool device to a network-connected storage.12. The method of claim 11, wherein the at least one operationalparameter includes movement of the tool device, and the at least onesensor mechanism is selected from the group consisting of anaccelerometer, magnetometer, photodetector and a gyroscope to measurethe movement of the tool device.
 13. The method of claim 11, wherein theat least one operational parameter includes power consumption of thetool device and the at least one sensor mechanism is a power metermechanism.
 14. The method of claim 11, wherein the at least oneoperational parameter includes electrical signals communicated from thetool device.
 15. The method of claim 11, further comprising determining,via a processing unit, a state of the tool device based on theinformation regarding the at least one operational parameter of the tooldevice.
 16. The method of claim 15, wherein the state of the tool deviceis a function of at least one of orientation of the tool device,location of the tool device, temperature of the tool device, power levelof the tool device, and operation of the tool device.
 17. The method ofclaim 15, further comprising preventing, via a control unit, use of thetool device upon the processing unit determining the tool device is in acertain state.
 18. The method of claim 11, wherein the at least onesensor mechanism is configured as a deformable and extendable substrateto be removably connected to different types of tool devices.
 19. Themethod of claim 11, wherein the tool device is selected from the groupconsisting of a machine, an actuator, a hand tool, and a power tool. 20.A sensor mechanism for monitoring usage of a tool device, the sensormechanism configured as a deformable and extendable substrate to beremovably connected to different types of tool devices, the sensormechanism further configured to detect at least one operationalparameter of a tool device and to communicate information regarding theat least one operational parameter of the tool device to anetwork-connected storage.